India’s tyre recycling sector, long plagued by fragmented operations and lax compliance, is undergoing a critical overhaul. With Gujarat’s recent approval for continuous pyrolysis plants, the industry is moving decisively towards cleaner, scalable and regulation-driven solutions. This shift signals more than a technological upgrade and it’s a rebuke of outdated batch systems and a call for formalisation, traceability and environmental accountability. As global demand for sustainable materials rises, India’s pivot positions it as a potential leader in circular economy practices. In conversation with TRRAI President Chetan Joshi, we explore how this development could redefine the future of tyre waste management at home and abroad.

India’s tyre recycling sector is on the cusp of a transformational shift with the Gujarat Pollution Control Board (GPCB) approving the establishment of continuous pyrolysis plants in the state. The move marks a significant departure from traditional batch-based tyre processing systems, promising to boost efficiency, environmental compliance and resource recovery at an industrial scale.

“This shift is nothing short of revolutionary,” said President of the Tyre and Rubber Recyclers Association of India (TRRAI) Chetan Joshi. “We’re moving from outdated, fragmented batch operations to streamlined, automated continuous pyrolysis systems. This is going to uplift the entire industry, from cleaner emissions to higher resource recovery, better traceability and serious investor interest. It sets a new national standard and will accelerate formalisation, industrial-scale operations and a far more sustainable approach across India.”

The approval has been met with optimism by recyclers and environmental advocates alike as it signifies a structural change in how end-of-life tyres will be handled in India, which is home to more than 1.8 million tonnes of tyre waste annually.

The Gujarat model mandates stringent adherence to environmental standards, particularly concerning air quality and emissions. Continuous pyrolysis plants approved under the new framework are required to incorporate top-tier pollution control mechanisms.

“We see compliance not as an obligation but as a core design principle. Our plants are being built with advanced air pollution control devices (APCDs), real-time emissions monitoring and automation that ensures consistent performance. We’re aligning with both GPCB and CPCB regulations through pro-active design, third-party audits and integrating global best practices. It’s not just about meeting today’s standards but staying ahead of tomorrow’s,” said Joshi.

The approach reflects a broader shift in the recycling sector, where regulatory compliance is no longer viewed as a hurdle but as a strategic advantage and market differentiator.

Industrial scale

Under the new directive, each continuous pyrolysis facility must operate at a minimum capacity of 60 tonnes per day (TPD). This scale reflects the government’s push to industrialise tyre recycling and eliminate inefficient, informal practices.

“Scaling to 60 TPD is a serious industrial commitment and it means heavy investment in automation, utilities, safety systems and logistics. But it’s also the only way forward. India generates over 1.8 million tonnes of end-of-life tyres annually. This scale allows us to handle the problem responsibly while creating traceable and economically viable recycling ecosystems,” Joshi said.

With India’s growing automotive base, the urgency to develop sustainable, high-capacity recycling infrastructure has never been higher.

One of the key advantages of continuous pyrolysis lies in its outputs that include valuable petrochemical byproducts like pyrolysis oil, sustainable fuels and recovered carbon black (rCB). These materials are increasingly in demand across a range of industries, from rubber manufacturing to renewable energy.

“These by-products are entering a new phase of global relevance. Recovered carbon black is being adopted in rubber, plastics and even pigments. Pyro oil, when upgraded, is a viable alternative fuel. We’re actively engaging with global buyers and certifiers to standardise and integrate these outputs into international supply chains. The world is ready for sustainable alternatives and it’s up to us to deliver with consistency and quality,” averred Joshi.

India’s entry into this global supply chain positions it not just as a recycler of waste but as a producer of sustainable industrial materials.

Circular economy

TRRAI views this milestone as more than an environmental success. It’s a step towards realising India’s vision of a circular economy, where tyre waste is fully reintegrated into the production cycle.

“We aim to be more than recyclers. We want to be circular economy enablers. That means building systems where tyre waste is traceable from collection to output, where value is recovered and re-injected into the economy. We’re developing collection infrastructure, digital traceability and offtake agreements with industries globally. This is not just about waste; it’s about resource optimisation and environmental stewardship,” Joshi explained.

Such a shift could significantly reduce the country’s carbon footprint while fostering job creation and industrial growth.

Despite the enthusiasm, industry leaders acknowledge that challenges remain, particularly in terms of adoption among legacy operators and infrastructure gaps.

“The biggest challenge is inertia as many operators are still working in the unorganised sector with outdated setups. Then there’s infrastructure as a hurdle as tyre collection networks are underdeveloped in many parts of India. To overcome this, we’re advocating policy changes, investing in reverse logistics and training the workforce. Regulatory clarity and enforcement will be key and we’re working closely with industry associations and government bodies to drive this,” said Joshi.

Stakeholders believe that education, investment and enforcement will be pivotal to ensuring widespread transition to continuous pyrolysis systems.

Global trends

Globally, countries like those in Europe and North America have already adopted advanced tyre recycling technologies. But Joshi believes India has a unique opportunity to leapfrog older systems and build world-class facilities from scratch.

“Europe and North America have a head start, especially in policy frameworks and end-use applications. But India’s opportunity lies in scale and adaptability. We can leapfrog legacy systems and build efficient, tech-driven plants from the ground up. If we get the ecosystem right – collection, compliance and capital – we can set new benchmarks, not just catch up. India could become a global hub for tyre recycling technology,” he said.

The industry’s fast pace of development combined with India’s manufacturing and engineering capabilities could make the country a case study in sustainable industrial transformation.

Innovations in emission reduction

In line with global best practices, TRRAI and its partners are integrating innovations to ensure safety and minimal environmental impact.

“We’re integrating closed-loop systems, AI-driven control logic and multi-stage gas cleaning technology. Real-time emissions data will be available both internally and to regulators. Safety protocols are built into every operational layer, from material feeding to shutdown procedures. We’ve also prioritised workforce training and regular third-party safety audits. The goal is to operate with zero compromise on health or the environment,” Joshi explained.

Such innovations are crucial not only to maintaining regulatory compliance but also to building public and investor confidence.

The entry of advanced technologies is expected to catalyse foreign investment and technical collaboration.

“Our approach is partnership-driven. We’re already working with European and Australian technology providers and are in discussions with institutional investors. We see India as a platform for co-creation, where global IP meets local scale and agility. Through industry associations like TRRAI, we’re building collaborative networks to ensure knowledge sharing, investment facilitation and joint innovation,” Joshi noted.

This strategy could help India become a global innovation hub for recycling technologies applicable across other emerging markets.

The vision

Looking to the long term, the industry’s goals extend far beyond domestic waste management. TRRAI envisions exporting its model to developing nations facing similar challenges.

“Our vision is bold but simple. It is to create a fully circular, scalable and replicable tyre recycling ecosystem. India should not only solve its own tyre waste crisis but become a global model for how emerging markets can tackle resource recovery. We see this model being exported to Southeast Asia, Africa and Latin America. With continuous pyrolysis, India can move from reactive recycling to proactive resource management on a global stage,” Joshi concluded.

As Gujarat lights the way with its approval of continuous pyrolysis plants, India’s tyre recycling sector is poised to become a beacon of innovation and sustainability – one that could shape the future of global recycling practices. n

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In a significant expansion of their existing recycling partnership, Alcoa Australia and Tyrecycle have commenced a new programme to repurpose used conveyor belts from Alcoa’s mining operations. The first reel of used belt was successfully delivered to Tyrecycle’s East Rockingham processing plant, marking a pivotal step in addressing a major waste stream. This initiative builds upon the companies' established contract for recycling off-the-road tyres and forms a core component of Alcoa’s broader corporate strategy to minimise, recycle and reuse waste generated by its Western Australian activities.

The ambitious programme will see approximately 32 kilometres of used conveyor belt transported to the facility over several months. In its initial phase, the collaboration aims to recycle 80 reels of belting. Tyrecycle will process an estimated 100 tonnes of this material weekly, transforming it into rubber crumb. This output will supplement the more than 300 tonnes of Alcoa’s used tyres the company already recycles annually. The primary focus of the recycling process is to reclaim the steel wire embedded within the belts and to convert the rubber into a versatile crumb product.

This crumb is destined for a wide array of practical applications, serving as a valuable additive in road construction bitumen, and as a raw material for creating surfaces for sports fields and playgrounds, adhesives and various moulded rubber goods. Tyrecycle emphasises a circular economy vision, aiming not just for repurposing but for eventually integrating recycled material back into the manufacturing of new conveyor belts. Since its inauguration, the East Rockingham facility has been instrumental in providing Western Australian mining operators with solutions to decarbonise their supply chains. This partnership with Alcoa simultaneously supports regional employment and advances shared environmental goals by diverting substantial rubber waste from landfill and giving it a productive new life.

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KRAIBURG TPE has introduced a new series of thermoplastic elastomers engineered specifically for e-bike handles. This THERMOLAST R RC/UV/AP series is designed to merge sustainability with high performance and improved ergonomics. A central feature of this material is its composition, which incorporates between 15 percent and 40 percent recycled content, directly addressing the industry's push towards more eco-conscious manufacturing.

The compound provides a soft-touch grip for enhanced rider comfort and control, alongside resistance to chemicals and ultraviolet light. Its lightweight nature contributes significantly to the overall reduction of e-bike weight, with some modern models now being up to 50 percent lighter than traditional designs. From a production standpoint, the material is formulated for multi-component injection moulding and bonds reliably to polypropylene, facilitating complex and innovative handlebar designs. Manufacturers can also select from a wide hardness range to customise the grip feel without sacrificing the material’s inherent durability or safety.

The performance of this TPE series is validated by extensive testing, including a two-year outdoor exposure that confirmed its resilience against harsh weather. It also maintains stability in temperatures up to 90°C, ensuring reliable long-term use. This product launch is part of KRAIBURG TPE's broader sustainability commitment, which includes developing bio-based TPEs, holding certifications for recycled content and providing Product Carbon Footprint data. The company's efforts have been recognised with an EcoVadis Gold Medal, and it has reaffirmed its commitment to Science Based Targets initiative (SBTi). This new material series positions KRAIBURG TPE as a pivotal partner in creating greener and more functional e-bike designs for a rapidly growing market.

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Bekaert's Ultra & Mega Tensile steel cord solutions have received the prestigious 2025 China Green Point Award for their significant role in advancing the tyre industry's shift towards low-carbon manufacturing.

This innovative reinforcement technology utilises high-strength steel, which allows for the production of lighter and more durable tyres while using less raw material. A key environmental benefit is the substantial reduction in rolling resistance, which directly improves vehicle fuel efficiency and leads to lower CO₂ emissions. Furthermore, the technology supports circular economy principles by incorporating steel with a high recycled content.

With over seven decades of expertise, Bekaert empowers leading global tyre manufacturers to create high-performance, sustainable tyres, thereby accelerating the transition to greener mobility on a large scale.

The company shared the achievement in a social media post: “A big thank you to our teams for their leadership in driving this achievement, and to our partners across the industry for making sustainable mobility a reality. This award is more than recognition: it’s proof of how materials innovation, powered by people, can accelerate change from the ground up – literally.”

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Ecolomondo Corporation, a Canadian developer of sustainable technology for recycling scrap tyres, is reporting significant commercial progress at its Hawkesbury TDP facility. The company is experiencing a substantial rise in demand for its recycled products, leading to strong sales growth.

A key development involves a major customer who, since mid-July 2025, has purchased 12 truckloads of recovered carbon black (rCB), representing approximately 276 metric tonnes. This client has signalled its intention to increase order volumes further as it transitions its business from another supplier. In another positive step, a second US-based customer has formally approved Ecolomondo's recovered carbon black for use in its manufacturing supply chain and is anticipated to commence bulk orders imminently. Additionally, the company has successfully shipped its 26th tanker of tyre-derived oil, amounting to 520 metric tonnes with an estimated value of USD 416,000.

This upward trend is reflected in the financial results. For the period from 1 January to 31 August 2025, revenues reached USD 640,986, a 91 percent increase compared to the USD 336,078 recorded during the same timeframe in 2024. This growth is largely attributed to the rising sales of recovered carbon black. To support the escalating production needs, Ecolomondo plans to hire and train additional personnel for the Hawkesbury facility. The company notes that, as expected during this operational ramp-up phase, the facility is not yet generating gross margins and continues to operate at a loss.

Jean-François Labbé, Interim CEO, Ecolomondo Corporation, said, “These milestones demonstrate the reliability of our production and the repeated nature of revenues we are building.”

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